Note: Descriptions are shown in the official language in which they were submitted.
A VACUUM DUST EXTRACTOR
FIELD
This invention relates to dust control or suppression in general. More
specifically, it
relates to an industrial particle extractor or collector and to a method of
collecting,
treating and discarding dust particles.
BACKGROUND
Extraction systems which remove airborne or entrained particles from
industrial
workplaces have been in use for a number of years. However, some of these
existing extraction systems simply extract and exhaust pollutants to
atmosphere
instead of removing them altogether. An effective way to deal with airborne
hazards
is to remove them at source, before they are dispersed throughout the
workplace
and, potentially, the external atmosphere.
This is especially true in the mining sector where accumulation and disruption
of dust
and other harmful airborne particles may cause serious environmental and
health
problems including pollution, contamination and respiratory disease. Instead
of
venting harmful pollutants to atmosphere, it is more advantageous to remove
such
particles from the air thereby preserving the environment and protecting
employees
from the potential health hazards associated with breathing in polluted air.
Conventional vacuum extraction units, which may be configured to collect air
pollutants at source, are plagued by poor pollutant handling procedures which
often
leads to collected air pollutants being reintroduced into atmosphere upon
emptying
of these vacuum extraction units.
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The Applicant has identified a need for an industrial dust extractor or
collector which
addresses or at least alleviates the drawbacks referred to above.
SUMMARY
According to a first aspect of the invention, there is provided a particle
extractor
assembly which includes:
a base;
a vacuum pump mounted to the base;
a powerplant mounted to the base, the powerplant being drivingly connected
to the vacuum pump;
a particle filter arranged upstream of the vacuum pump in order to filter out
particles upstream of the vacuum pump; and
a collector drum having an inlet for drawing particles into an inner cavity of
the
drum and an outlet leading to the vacuum pump, wherein the vacuum pump is
configured to create suction through the assembly to draw particles into the
collector
drum via the inlet, the collector drum being configured to rotate relative to
the base
about a rotation axis in order to mix contents of the drum and to discharge
the
contents of the drum.
The particle extractor assembly may include a tank for holding an additive.
The
additive may be for admixture with the contents of the collector drum to
create a
slurry or paste. The additive may be a chemical additive. The additive may be
a
polymeric additive. To this end, the assembly may include an additive delivery
system which is configured to introduce additive from the tank into the inner
cavity of
the collector drum. The additive delivery system may include a delivery pump
which
is configured to pump additive from the tank to the inner cavity of the
collector drum.
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The powerplant may be an electrical motor. The powerplant may be directly
coupled
to the vacuum pump by way of a flexible coupling. Alternatively, the
powerplant may
be a combustion engine.
The particle extractor assembly may include a drum arrangement which includes:
the collector drum;
a drum mounting which is operatively connected to the base and is configured
to receive the collector drum; and
a drum drive drivingly connected to the collector drum and configured to
rotate the collector drum relative to the drum mounting and about its rotation
axis.
The drum drive may be configured to rotate the collector drum about its
rotation axis
in one of two possible directions.
The drum mounting may include a pair of cradles or braces which extend at
least
partially around a periphery of the collector drum and are configured to
receive the
drum. The cradles may include rollers which facilitate rotation of the
collector drum
relative to the cradles. The cradles may be interconnected by way of
peripherally
spaced apart, elongate braces. The collector drum may include a convexly
curved,
downstream portion toward the outlet, a cylindrical portion connected to the
convexly
curved portion, and a frusto-conical portion which is connected to the
cylindrical
portion and tapers to the operative upstream inlet of the drum. The collector
drum
may include a removable lid which is configured to close the inlet, at least
in part.
The collector drum may be substantially horizontally orientated. In other
words, the
inlet and outlet may be coaxially aligned and may lie within a horizontal
plane.
The assembly may include a silencer or muffler which is operatively in fluid
flow
communication with the vacuum pump, downstream of the vacuum pump and
configured to lower emission sounds of the assembly to equal to, or below 80
dB.
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The assembly may include an electrical control panel which provides an
operator
interface for controlling the assembly. The assembly may include one or more
load
sensors. To this end, the assembly may include an electronic control unit. The
load
sensors may be coupled to or communicatively linked to the control unit. The
electronic control unit may be configured to interrupt operation of the vacuum
pump
if the load sensors indicate that the collector drum is overloaded. The
control panel
may include a load indicator which indicators an overload condition to the
operator.
The assembly may include an emergency stop to turn off power to the vacuum
pump.
The assembly may be configured for use in underground mining operations.
Accordingly, the assembly may be intrinsically safe or otherwise electrically
safe for
underground mining operations. The assembly may include protective panels or
guards, mounted to the base, which guard, by at least partially enclosing, the
components of the assembly.
The particle filter may be arranged in fluid flow communication between the
collector
drum and the vacuum pump, i.e. downstream of the collector drum and upstream
of
the vacuum pump. The particle filter may include a plurality of filter bags or
socks
housed within a filter housing. The filter housing may have a downwardly
orientated
inspection opening which is operatively closed by an inspection lid.
The collector drum may be configured to mix contents of the drum when the
collector
drum is rotated relative to the base in a first direction. Furthermore, the
collector
drum may be configured to discharge or expel its contents from the inner
cavity via
the inlet when rotated about its rotation axis in a second direction. To this
end, the
collector drum may include a plurality of internal vanes which are arranged to
assist
discharging of the contents from the drum when rotated in the second
direction.
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The assembly may include a pressurised air supply, i.e. a compressor which is
configured to clean the filter bags of the particle filter, intermittently, by
pulsating air
through the filter bags. The filter bags may be cleaned, in situ, by way of
air pulses.
The method of cleaning is referred to as pulse jet cleaning. The particle
extractor
assembly may include a pair of pressure sensors configured to measure a
pressure
differential across the particle filter in order to determine when the
particle filter
needs to be cleaned/emptied or otherwise maintained. The pressure sensors may
be arranged across an inlet and outlet of the particle filter.
The particle extractor assembly may be mobile or portable. The assembly may be
transportable by a dedicated mining vehicle.
The invention extends to a method of collecting dust and/or other airborne
particles
using a particle extractor assembly as described above, the method including:
collecting airborne particles in the collector drum of the particle extractor
assembly by operating the vacuum pump to create suction through the assembly;
treating contents of the drum using an additive by delivering the additive to
the collector drum to form a slurry or paste; and
discharging the contents from the collector drum.
The collecting step may include, intermittently cleaning the particle filter
by pulsating
filter bags of the particle filter with pressurised air. The collecting step
may include
sensing, using a least two pressure sensors, a pressure differential across
the
particle filter in order to determine when the particle filter needs to be
cleaned.
The step of treating may include rotating the collector drum relative to the
base of
the particle extractor assembly in a first direction in order to mix the
contents. The
treating step may further include actively introducing the additive to the
collector
drum.
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The method may include the step of, prior to treating the contents of the
drum,
sensing, using one or more load sensors, when the collector drum is full and
automatically turning off the pump.
The discharging step may include rotating the collector drum relative to the
base in a
second direction opposite to the first direction.
The method may include intermittently cleaning the particle filter of the
assembly by
pulsating filter elements of the particle filter with air.
In accordance with another aspect of the invention, there is provided a
particle
extractor assembly which includes:
a base;
a vacuum pump mounted to the base;
a powerplant mounted to the base, the powerplant being drivingly connected
to the vacuum pump;
a particle filter arranged upstream of the vacuum pump in order to filter out
particles upstream of the vacuum pump;
a drum arrangement which includes:
a collector drum having an inlet for drawing particles into an inner
cavity of the collector drum and an outlet leading to the particle filter;
a drum mounting which is operatively connected to the base and is
configured to receive the collector drum; and
a drum drive drivingly connected to the collector drum and configured
to rotate the collector drum relative to the drum mounting about a rotation
axis; and
an additive delivery system which is mounted to the base and which includes
a tank for holding an additive, the additive delivery system being configured
to
introduce additive from the tank into the inner cavity of the collector drum,
wherein
the vacuum pump is configured to create suction through the particle extractor
assembly to draw particles into the collector drum via the inlet, the
collector drum
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being configured, upon rotation of the collector drum about its rotation axis,
to mix
the additive introduced into the inner cavity by the additive delivery system
with the
particles in the inner cavity of the collector drum to form a slurry.
The particle extractor assembly may be configured, upon rotation of the
collector
drum about its rotation axis, to discharge the slurry from the inner cavity of
the
collector drum.
The base may include a first platform and a pivot platform, the pivot platform
being
articulated to the first platform. The particle extractor assembly may include
an
actuator operatively connected between the first platform and the pivot
platform. The
actuator may be configured pivotally to displace the pivot platform relative
to the first
platform about a pivot axis which is transverse to the rotation axis of the
collector
drum between a lowered position in which the pivot platform abuts the first
platform
and is coplanar therewith and a discharge position in which the pivot platform
is
inclined with respect to the first platform.
The drum arrangement and the particle filter may be mounted to the pivot
platform
and may be configured for pivotal displacement therewith about the pivot axis.
The
actuator may include a hydraulic pump which is mounted to the first platform
and a
hydraulic cylinder which is connected between the first platform and the pivot
platform, the hydraulic pump being configured to actuate the hydraulic
cylinder to
displace the pivot platform between its lowered and discharge positions.
When the pivot platform is in its discharge position, an operatively
downstream end
of the collector drum defining the outlet may be raised with respect to the
inlet of the
collector drum to facilitate discharge of the slurry held in the inner cavity
of the
collector drum from the collector drum via the inlet.
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The drum drive may be configured to rotate the collector drum about its
rotation axis
in opposite, first and second directions, wherein, when the collector drum is
rotated
relative to the base in the first direction, the collector drum is configured
to mix
contents of the collector drum, and, when rotated about its rotation axis in
the
second direction, the collector drum is configured to discharge or expel its
contents
from the inner cavity via the inlet. The collector drum may include a
plurality of
internal vanes which are arranged to assist discharging of the contents from
the
collector drum when rotated in the second direction.
The particle filter may be arranged downstream of the collector drum and
upstream
of the vacuum pump. The particle filter may include a plurality of filter bags
which are
housed within a filter housing at a higher elevation than the outlet of the
collector
drum. The filter housing may include a downwardly depending hopper which is
connected in fluid flow communication to the outlet of the collector drum.
The particle extractor assembly may include a pressurised air supply which is
configured to clean the filter bags of the particle filter, intermittently, by
pulsating air
through the filter bags, in reverse, thus serving to dislodge particles
potentially
clogging the filter bags and ejecting the dislodged particles back into the
collector
drum via the hopper arranged below the filter bags.
The particle extractor assembly may include a pair of pressure sensors
arranged
across an inlet and outlet of the particle filter and configured to measure a
pressure
differential across the particle filter in order to determine when the
particle filter
needs to be cleaned.
The pressurised air supply may include a compressor having a primary/master
pressure vessel and a downstream secondary/slave pressure vessel which is
connected to nozzles configured to pulsate air through the filter bags. The
primary
and secondary pressure vessels may be in fluid flow communication.
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The additive delivery system may include a delivery pump which is configured
to
pump additive from the tank to the inner cavity of the collector drum.
The drum mounting may include a pair of cradles which extend at least
partially
around a periphery of the collector drum and are configured to receive the
drum, the
cradles including rollers which facilitate rotation of the collector drum
relative to the
cradles. The collector drum may include a downstream portion toward the
outlet, a
cylindrical portion connected to the downstream portion, and a frusto-conical
portion
which is connected to the cylindrical portion. The frusto-conical portion may
taper to
the operative upstream inlet of the collector drum. The collector drum may
include a
removable lid which is configured to close the inlet, at least in part. An
inner surface
of the collector drum may have a non-stick coating.
The particle extractor assembly may include a silencer which is operatively in
fluid
flow communication with the vacuum pump, downstream of the vacuum pump and is
configured to lower emission sounds of the particle extractor assembly to
equal to, or
below 80 dB, an exhaust of the particle extractor assembly being operatively
upwardly orientated.
The particle extractor assembly may include an electrical control panel and an
electronic control unit which provide an operator interface for controlling
the particle
extractor assembly, and one or more load sensors which are coupled to or
communicatively linked to the electronic control unit, wherein the electronic
control
unit is configured to interrupt operation of the vacuum pump if the load
sensors
indicate that the collector drum is overloaded. The electrical control panel
includes a
load indicator which is configured to indicator an overload condition to an
operator.
The particle extractor assembly may further include protective panels, mounted
to
the base, which guard, by at least partially enclosing the assembly, an
operator from
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components of the particle extractor assembly. The particle extractor assembly
may
be portable.
The invention extends to a method of collecting dust and/or other airborne
particles
using a particle extractor assembly as described above, the method including:
collecting airborne particles in the collector drum of the particle extractor
assembly by operating the vacuum pump to create suction through the particle
extractor assembly;
treating contents of the collector drum using an additive by delivering the
additive to the collector drum to form a slurry; and
discharging the contents from the collector drum.
Collecting may include intermittently cleaning the particle filter by
pulsating filter bags
of the particle filter with pressurised air.
Collecting may include sensing, using a least two pressure sensors, a pressure
differential across the particle filter in order to determine when the
particle filter
needs to be cleaned.
Treating may include rotating the collector drum relative to the base of the
particle
extractor assembly in a first direction in order to mix the contents.
Discharging may include rotating the collector drum relative to the base in a
second
direction opposite to the first direction and pivotally displacing a pivotal
platform of
the base to a discharge position in which it is inclined with respect to a
remainder of
the base.
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BRIEF DESCRIPTION OF DRAWINGS
The invention will now be further described, by way of example, with reference
to the
accompanying drawings.
In the drawings:
Figure 1 illustrates a three-dimensional view of a first embodiment of a
particle extractor assembly in accordance with the invention, where protective
panels
or guards have been omitted for the sake of clarity;
Figure 2 illustrates another three-dimensional view of the particle extractor
assembly, from an opposite side;
Figure 3 shows a side elevation of the particle extractor assembly of Figure
1;
Figure 4 shows a front-end view of the particle extractor assembly;
Figure 5 shows a plan view of a base of the particle extractor assembly;
Figure 6 shows a three-dimensional view of a second embodiment of the
particle extractor assembly in accordance with the invention;
Figure 7 shows a plan view of the particle extractor assembly of Figure 6;
Figure 8 shows a three-dimensional view of the particle extractor assembly
from a rear;
Figure 9 shows a right side view;
Figure 10 shows a front three-dimensional view of the particle extractor
assembly of Figure 6, absent protective panels for the sake of clarity;
Figure 11 shows a right side view of the particle extractor assembly of Figure
10;
Figure 12 shows a top view of the particle extractor assembly of Figure 10;
Figure 13 shows a left side view;
Figure 14 shows an enlarged or detailed view of part of the particle extractor
assembly shown in Figure 13;
Figure 15 shows another detailed view from a different angle; and
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Figure 16 shows a right side view of the particle extractor assembly of Figure
9 in a discharge position.
DETAILED DESCRIPTION OF AN EXAMPLE EMBODIMENT
The following description of the invention is provided as an enabling teaching
of the
invention. Those skilled in the relevant art will recognise that many changes
can be
made to the embodiments described, while still attaining the beneficial
results of the
present invention. It will also be apparent that some of the desired benefits
of the
present invention can be attained by selecting some of the features of the
present
invention without utilising other features. Accordingly, those skilled in the
art will
recognise that modifications and adaptations to the present invention are
possible
and can even be desirable in certain circumstances, and are a part of the
present
invention. Thus, the following description is provided as illustrative of the
principles
of the present invention and not a limitation thereof.
In the Figures, two embodiments of a particle extractor assembly in accordance
with
the invention have been illustrated. Although it is not limited to this
application, the
embodiments of the particle extractor assembly find application in the mining
sector
and are used to extract and collect dust and/or other airborne pollutants from
a
workface during, for example, drilling operations. Accordingly, the particle
extractor
assembly may be referred to as a vacuum dust extractor or collector. In
Figures 1 to
4, reference numeral 10 designates a first embodiment of the particle
extractor
assembly and reference numeral 100 designates a second, preferred embodiment
of
the particle extractor assembly in Figures 6 to 16.
The particle extractor assembly 10, 100 is portable and can be transported to
different locations as required. To this end, the particle extractor assembly
10, 100
includes a base 12 which is configured to be transported by a mining vehicle
(not
shown). The base 12 includes a skid which includes a pair of longitudinally
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extending, laterally spaced apart supports 14 which are interconnected by a
plurality
of spaced apart lateral struts 13. A lower profile of the base 12 corresponds
to, and
renders it transportable by, the mining vehicle.
Referring specifically to Figures 1 to 4, the particle extractor assembly 10
further
includes a centrifugal vacuum pump 15 (see Figures 2 and 3), and a powerplant
in
the form of an electrical motor 16 which is drivingly connected to the vacuum
pump
by way of a flexible coupling. The particle extractor assembly 10 further
includes
a drum arrangement which includes a large hollow collector drum 17, a drum
10 mounting 18 which is operatively connected to the base 12 and is
configured to
receive the collector drum 17 for rotation about a rotation axis X, and a drum
drive
19 which is drivingly connected to the collector drum 17 and is configured to
rotate
the collector drum 17 relative to the base 12 and the drum mounting 18 about
its
substantially horizontal rotation axis X, in any one of two opposite
directions. The
15 drum drive 19 is configured to rotate the collector drum 17 in first and
second
directions relative to the drum mounting 18. In the first (anti-clockwise)
direction,
rotation of the collector drum 17 results in mixing of the contents of the
collector
drum 17. In the second (clockwise) direction, the collector drum 17 is
configured to
discharge its contents via an inlet. The drum drive 19 may include an
electrical
motor and an associated gearbox which is drivingly connected to the collector
drum
17.
The collector drum 17 includes an inlet, closed by an inlet cover 24, which
leads into
an inner cavity and an outlet which leads from the inner cavity in a
downstream
direction. The inlet and outlet may be coaxially aligned and may line within a
substantially horizontal plane.
The first embodiment of the particle extractor assembly 10 further includes a
particle
filter 20 which is configured to filter out harmful, oversized particles
upstream of the
vacuum pump 15 in order to prevent such particles from damaging the vacuum
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pump 15. The particle filter 20 includes a metallic filter housing 21 which
houses a
plurality of filter bags or socks (not shown). The filter housing 21 has a
downwardly
orientated inspection or discharge opening which is operatively closed by an
inspection lid 22. By way of suitable piping, which includes a swivel joint 23
(see
Figure 3) disposed toward the outlet of the collector drum 17 to facilitate
rotation of
the collector drum 17 relative to the piping and other components, the
collector drum
17 is connected in fluid flow communication with the downstream particle
filter 20,
and, in turn, the particle filter 20 is connected in fluid flow communication
to the
downstream vacuum pump 15. On the downstream side of the vacuum pump 15,
clean filtered air is vented to atmosphere via an upright muffled exhaust 25.
The particle extractor assembly 10 further includes a control panel 26 which
includes
an electronic control unit (not shown). The control panel 26 provides an
interface
through which an operator can control the various components of the particle
extractor assembly 10 by switching them on/off. Furthermore, the particle
extractor
assembly 10 is provided with emergency cut-out switches which can be used to
interrupt operation of the vacuum pump 15, drum drive 19 and/or electrical
motor 16.
In addition, the assembly includes a pressurised air supply in the form of a
compressor 27 which is configured to clean the filter bags of the particle
filter 20 by
intermittently pulsating the bags housed within the filter housing 21 with
pressurised
air. To this end, suitable hoses run from the compressor 27 to an inside of
the filter
housing 21. An adjustable pulse interval may be set to between 30 and 60
seconds
or as otherwise desired. This interval is adjustable by the operator to suit
the
material being vacuumed.
The particle extractor assembly 10 further includes a tank 28 for holding an
additive
for mixing with the contents of the collector drum 17 to create a slurry or
paste which
can be effectively discharged. The additive mixes and binds with dust
particles to
form the slurry. This fluidised form of the vacuumed material is easier to
handle and
discharge, thus lowering contamination and pollution. To this end, the
particle
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extractor assembly 10 includes an additive delivery system which is configured
to
introduce additive from the tank 28 into the inner cavity of the collector
drum 17. The
additive delivery system includes a dosing or delivery pump which is
configured to
pump additive from the tank 28 to the inner cavity of the collector drum 17
via a
connection made between the tank 28 and the collector drum 17 at the swivel
joint
23.
The collector drum 17 includes an operatively upstream frusto-conical portion
30, a
narrow end of which defines the inlet and is shaped to receive the inlet cover
24.
The frusto-conical portion 30 is connected to a downstream circular
cylindrical
portion 31 which, in turn, is connected to a convexly curved downstream end
portion
32 which defines the outlet which is operatively connected to the swivel joint
23. An
elongate vacuum pipe or hose (not shown) is operatively connected to the inlet
cover
24 and sucks particles into the collector drum 17. The drum mounting 18
includes a
pair of peripherally extending, longitudinally spaced apart braces or cradles
35 which
at least partially wrap around the collector drum 17 and are configured to
receive the
collector drum 17. The cradles 35 are C-shaped and are mounted to the base 12.
The cradles 35 are interconnected by way of peripherally spaced apart,
elongate
braces 37. Each cradle 35 includes four, peripherally spaced apart rollers 36,
mounted between opposing flanges of the cradle 35, which facilitate rotation
of the
collector drum 17 relative to the drum mounting 18. The drum drive 19 is
configured
to rotate the collector drum 17 in clockwise and anticlockwise directions
relative to
the base 12.
In use, the particle extractor assembly 10 is transported to an above ground
or
underground workface. Once in place, the vacuum hose is correctly positioned
in
relation to the drill (not shown) in order to extract debris and dust as the
drill
operates. It will be appreciated that the vacuum hose may be connected
directly to a
drill boom or arm of a drill rig to collect particles at the workface.
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Once all the precautionary safety measures have been taken, the electric motor
16
and vacuum pump 15 are turned on. The vacuum pump 15 creates suction and
draws dust and other particles into the collector drum 17 via the hose and
inlet. At
this stage the collector drum 17 is stationary and does not rotate. Entrained
finer or
lighter particles will pass through the drum 17 via the outlet and into the
particle filter
20 before the air passes through the vacuum pump 15 and is exhausted via the
muffled exhaust 25. The particle extractor assembly 10 includes one or more
load
sensors (not shown) which are configured to sense a load of the collector drum
17.
The load sensors may be coupled to the electronic control unit which is
configured
automatically to interrupt operation of the motor 16 and vacuum pump 15 once
the
control unit has established via the load sensors that the collector drum 17
has
reached its maximum load or capacity. A load indicator e.g. a red light,
gauge, dial
or buzzer, may serve to indicate to the operator that the collector drum 17
has
reached capacity. Whilst the vacuum pump 15 is running, the air compressor 27
intermittently cleans the filter bags of the particle filter 20 by pulsating
the bags with
pressurised air. Accordingly, the filter bags are cleaned, in situ, by way of
air pulses.
This method of cleaning is referred to as pulse jet cleaning. The particle
extractor
assembly 10 includes a pair of pressure sensors 40 configured to measure a
pressure differential across the particle filter 20 in order to determine when
the
particle filter 20 needs to be cleaned/emptied via the inspection opening or
otherwise
maintained. The pressure sensors 40 are arranged across an inlet and outlet of
the
particle filter 20 and are configured to measure the pressure difference
across the
inlet and outlet of the filter 20.
Once the collector drum 17 is full, the vacuum pump 15 and motor 16 are turned
off
and the mining vehicle transporting the assembly 10 may be driven to an
appropriate
dumping site. In addition, the drum drive motor 19 is started and the
collector drum
17 is rotated relative to the base 12 and drum mounting 18 in an anti-
clockwise
direction about the rotation axis X. At the same time, the dosage or delivery
pump is
started in order to introduce the additive into the inner cavity of the
collector drum 17.
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Due to rotation of the collector drum 17, the contents of the drum 17 mixes
with the
additive and forms a slurry or paste. Once an adequate amount of additive has
been
introduced and mixed with the drum contents, the delivery pump is turned off.
Once the vehicle has reached the dumping site, the drum drive motor 19 is
stopped
and rotation of the collector drum 17 is reversed, i.e. it is rotated in a
clockwise
direction by operating the drum drive motor 19 in reverse in order to
discharge the
slurry from the collector drum 17 via the inlet. This necessitates prior
removal of the
inlet cover 24 or connection of a discharge hose. The same hose used for
vacuuming may also be used for discharging. Angled vanes inside the collector
drum 17 facilitate expulsion of the slurry from the inner cavity via the
inlet, when the
drum 17 is rotated in a clockwise direction. Once the slurry has been dumped,
vacuuming can be restarted.
The second, preferred embodiment of the particle extractor assembly 100 is
shown
in Figures 6 to 16. The same reference numerals used above have again been
used
to refer to similar parts of the second embodiment. In principle, operation of
the
second embodiment is similar to the first embodiment. However, a number of
design
changes, which will be elaborated on below, have been introduced to improve
performance of the second embodiment of the particle extractor assembly 100
when
compared to the first embodiment. Referring now to Figure 16, in particular,
the base
12 of the second embodiment of the particle extractor assembly 100 includes a
first
stationary platform 12.1 which includes the skid 120 and a sub-frame 121
mounted
to the skid 120, and a second pivot platform 12.2 which is articulated to the
first
stationary platform 12.1, by way of a pair of laterally spaced apart hinges
122
arranged toward a front end of the skid 120, for pivotal displacement relative
to the
first stationary platform 12.1 about a transverse pivot axis P (see Figures 6
and 14).
Similar to the first embodiment, the second embodiment of the particle
extractor
assembly 100 also includes a vacuum pump 150 mounted to the first stationary
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platform 12.1 of the base 12, and a powerplant in the form of an electrical
motor 160
also mounted to the first stationary platform 12.1 adjacent to the vacuum pump
150.
The electrical motor 160 is drivingly connected to the vacuum pump 150 by way
of a
drive belt and pulley arrangement. The particle extractor assembly 100 further
includes a drum arrangement which includes a generally circular cylindrical
collector
drum 170 having an inlet for drawing particles into an hollow inner cavity of
the
collector drum 170 and an outlet leading to a particle filter 200. The drum
arrangement further includes a drum mounting which is connected to the second
pivot platform 12.2 of the base 12 and is configured to receive and support
the
collector drum 170 and a drum drive drivingly connected to the collector drum
170
and configured to rotate the collector drum 170 relative to the drum mounting
about
a rotation axis X (see Figures 9 and 11). The particle filter 200 is arranged
upstream
of the vacuum pump 150 in order to filter out particles upstream of the vacuum
pump
150. However, the particle filter 200 is mounted to the second pivot platform
12.2
and is configured for pivotal displacement relative to the first stationary
platform 12.1
about the pivot axis P, together with the drum arrangement, as can be seen in
Figure
16.
Referring to Figures 11 to 15, the drum mounting includes a pair of
longitudinally
spaced apart annular cradles 350 which extend at least partially around a
periphery
of the collector drum 170 and are configured to support and receive the
collector
drum 170. Referring specifically to Figures 14 and 15, one cradle 350 of the
pair
includes the drum drive which includes an electrical drum drive motor 190
which has
a solid shaft connected to a drive gear 191 which drivingly engages a
peripheral ring
gear 192 of the collector drum 170. This cradle 350 includes a plurality of
idler gears
351 which also engage the ring gear 192 at peripherally spaced apart
positions. The
other cradle 350 of the pair includes a plurality of idler rollers 360 which
engage a
peripheral collar 352 of the collector drum 170. The drum drive motor 190 and
drive
and idlers gears 191. 351 and rollers 360 together facilitate rotation of the
collector
drum 170 relative to the cradles 350 about the rotation axis X.
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The particle extractor assembly 100 also includes an additive delivery system
which
includes a stainless-steel tank 280 for holding a water/additive solution. The
tank
280 is mounted to the first stationary platform 12.1 of the base 12. The
additive
delivery system further includes a delivery pump 281 (see Figure 14) which is
configured to pump the additive from the tank 280 into the inner cavity of the
collector drum 170, via a line which leads into the inner cavity, in order to
form a
slurry with particles sucked into the inner cavity by the vacuum pump 150.
As can best be seen in Figures 15 and 16, the particle extractor assembly 100
includes an actuator operatively connected between the first stationary
platform 12.1
and the second pivot platform 12.2. The actuator is configured pivotally to
displace
the second pivot platform 12.2 relative to the first stationary platform 12.1
about the
pivot axis P which is transverse to the rotation axis X of the collector drum
170
between a lowered position shown in Figures 6 to 15 in which the second pivot
platform 12.2 abuts the first stationary platform 12.1 and is coplanar
therewith and a
discharge position, shown in Figure 16, in which the second pivot platform
12.2 is
inclined with respect to the first stationary platform 12.1. The actuator
includes a
hydraulic fluid reservoir 290 (see Figures 10 and 11) and an electric motor
and
hydraulic pump 291 (see Figures 13 to 15) which are mounted to the first
stationary
platform 12.1 and a telescopically extendable hydraulic cylinder 292 which is
operatively connected between the first stationary platform 12.1 and a clevis
293
protruding upwardly from a rear of the second pivot platform 12.2. The
hydraulic
pump 291 is configured to actuate the hydraulic cylinder 292 to displace the
second
pivot platform 12.2 between its lowered and discharge positions.
As can be seen in Figure 16, when the hydraulic cylinder 292 is telescopically
extended by the hydraulic pump 291, it lifts the rear end of the second pivot
platform
12.2 including the drum arrangement and particle filter 200 such that the
outlet of the
collector drum 170 is raised with respect to the inlet to facilitate discharge
of the
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CA 3047947 2019-06-25
slurry held in the inner cavity of the collector drum 170 from the collector
drum 170
via the inlet.
As in the first embodiment, the drum drive motor 190 is configured to rotate
the
collector drum 170 about its rotation axis X in opposite, first and second
directions.
When the collector drum 170 is rotated relative to the base 12 in the first
direction,
the collector drum is configured to mix contents of the collector drum, and,
when
rotated about its rotation axis X in the second direction, the collector drum
170 is
configured to discharge or expel its contents from the inner cavity via the
inlet. The
collector drum 170 also includes a plurality of internal vanes which are
arranged to
assist discharging of the contents from the collector drum 170 when rotated in
the
second direction.
The particle filter 200 includes a plurality of filter bags 201 (see Figures
10 and 12)
which are housed within a box-shaped filter housing 210 at a higher elevation
than
the outlet of the collector drum 170. The filter housing 210 includes a
downwardly
depending hopper 212 which is continuously connected to an upper part of the
box-
shaped filter housing 210 and is connected in fluid flow communication to the
outlet
of the collector drum 170 via swivel joint 23. The particle extractor assembly
100
further includes a pressurised air supply in the form of a compressor 270
having a
primary/master pressure vessel 271 and a secondary/slave pressure vessel 272
for
temporarily storing compressed air. The compressed air of the compressor 270
is
used to clean the filter bags 201 of the particle filter 200, intermittently,
by pulsating
air through the filter bags 201, in reverse, thus serving to dislodge
particles
potentially clogging the filter bags 201 and ejecting the dislodged particles
back into
the collector drum 170 via the hopper 212 and outlet of the collector drum 170
arranged below the filter bags 201. The slave pressure vessel 272 is connected
to
nozzles via air tubes 273 and is configured to pulsate air through the filter
bags 201.
On the downstream side of the vacuum pump 150, clean filtered air is vented to
atmosphere via an upright muffled exhaust 25.
CA 3047947 2019-06-25
Referring now to Figures 11 and 12, the collector drum 170 includes a
downstream
portion 171 which tapers toward the outlet, a circular cylindrical portion 172
connected to the downstream portion 171, and a frusto-conical portion 173
which is
connected to the circular cylindrical portion 172. The frusto-conical portion
173
tapers to the operative upstream inlet of the collector drum 170. The
collector drum
170 also includes a removable lid which is configured to close the inlet, at
least in
part. To facilitate easy discharge of the slurry and to prevent setting and
binding
thereof with an inner surface of the collector drum 170, the inner surface of
the
collector drum 170 has a non-stick coating.
The particle extractor assembly 100 includes an electrical control panel 260
mounted
to the first stationary platform 12.1. An electronic control unit is housed
within the
electrical control panel 260. An operator interface (not shown) is provided
for
controlling the particle extractor assembly 100. By way of one or more load
sensors
(not shown) which are coupled to or communicatively linked to the electronic
control
unit, operation of the vacuum pump 150 may be interrupted if the load sensors
indicate that the collector drum 170 is overloaded. The electrical control
panel 260
includes a load indicator which is configured to indicate an overload
condition to an
operator.
The particle extractor assembly 100 includes a plurality of planar protective
panels
320, some of which are hingedly mounted to a frame 322 which, in turn, is
mounted
to an outer periphery of the first stationary platform 12.1 of the base 12.
The
protective panels 320 and frame 322 guard an operator or other workers from
harm
by at least partially enclosing moving or hazardous parts of the particle
extractor
assembly 100. A flexible and extendable concertina hose (not shown) connects a
T-
piece 213, depending from the particle filter 200, in fluid flow communication
with the
vacuum pump 150 to complete a suction line passing through the assembly 100.
An
electrical cable reel 300 holds an electrical cable which is used to feed
electrical
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CA 3047947 2019-06-25
power to the 45kW electrical motor 160. The cable reel 300 is mounted to a
rear of
the frame 322 of the assembly 100. Although this has not been clearly
illustrated, the
electrical cable reel 300 may be configured to pivot relative to the frame 322
between a stowed position and an operative reeling-in position to facilitate
reeling of
an electrical cable on the reel 300 using a manual crank spanner which
attaches to
the reel 300. The drum mounting also includes protective panels which
partially
enclose the collector drum 170, cradles 350 and drum drive motor 190.
The second embodiment of the particle extractor assembly 100 has the following
advantages over the first embodiment when compared to the first embodiment.
First,
introduction of the actuator including the hydraulic cylinder 292 which is
configured
pivotally to displace the second pivot plafform 12.2 holding the collector
drum 170
and particle filter 200 between its lowered and discharge positions, ensures
that at
least a majority portion of the slurry held in the inner cavity is discharged
or ejected
therefrom despite the fact that the assembly 100 may not necessarily be
positioned
on a level surface. Secondly, second handling of ejected dust particles
dislodged
from the filter bags is obviated by reintroduction of the ejected particles
into the
collector drum 170 via the hopper 212. In the first embodiment of the particle
extractor assembly 10, the dislodged particles where ejected via the
inspection
opening covered by the removable inspection lid 22 which necessitated second
handling of those particles. Furthermore, the introduction of the slave
pressure
vessel 272 obviates regular start-ups of the compressor 270 to repressurise a
pressure vessel each time pressure is reduced due to pulsation of air through
the
filter bags. Recurring start-ups shorten the life of the compressor 270. In
the
master/slave configuration, the compressor 270 only needs to start-up once
pressure in the slave pressure vessel has drop below a predetermined
threshold. Air
in the larger master pressure vessel is then transferred to the slave pressure
vessel
to repressurise it and the compressor 270 only starts-up then to repressurise
the
master pressure vessel. Previously, the compressor 270 started-up more
frequently
as pressure in the single pressure vessel dropped.
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The Applicant believes that the particle extractor assembly 10, 100 in
accordance
with the invention provides an effective solution for overcoming dust
pollution issues
by implementing dust suppression, collection, handling and ejection. Instead
of
venting harmful pollutants to atmosphere, the assembly 10, 100 is configured
effectively to remove such particles from the air at source thereby preserving
the
environment and protecting employees from health hazards associated with
breathing in polluted air. It is to be appreciated that the particle extractor
assembly
may be connected directed to a drill arm of a drill rig to extractor air
pollutants at the
source. Control of the particle extractor assembly may also be integrated with
a
control interface of the drill rig.
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